Coated article with low-E coating including tin oxide interlayer

ABSTRACT

A coated article is provided which may be heat treated (e.g., thermally tempered) in certain instances. In certain example embodiments, an interlayer of or including a metal oxide such as tin oxide is provided under an infrared (IR) reflecting layer so as to be located between respective layers comprising silicon nitride and zinc oxide. It has been found that the use of such a tin oxide inclusive interlayer results in significantly improved mechanical durability, thermal stability and/or haze characteristics.

This application is a continuation of Application Ser. No. 12/929,404,filed Jan. 21, 2011 now U.S. Pat. No. 8,124,237, which is a CON of Ser.No. 11/641,827, filed Dec. 20, 2006 (now U.S. Pat. No. 7,897,260), whichis a DIV of Ser. No. 10/797,561, filed Mar. 11, 2004 (now U.S. Pat.7,217,460), the entire disclosures of which are all hereby incorporatedherein by reference in this application.

This invention relates to a coated article including a low-E coating. Incertain example embodiments, an interlayer comprising tin oxide or thelike may be provided under an infrared (IR) reflecting layer and inparticular between respective layers comprising silicon nitride and zincoxide. In certain example embodiments, the coated article may be heattreated (e.g., thermally tempered, heat bent and/or heat strengthened).Coated articles according to certain example embodiments of thisinvention may be used in the context of insulating glass (IG) windowunits, vehicle windows, other types of windows, or in any other suitableapplication.

BACKGROUND OF THE INVENTION

Coated articles are known in the art for use in window applications suchas insulating glass (IG) window units, vehicle windows, and/or the like.It is known that in certain instances, it is desirable to heat treat(e.g., thermally temper, heat bend and/or heat strengthen) such coatedarticles for purposes of tempering, bending, or the like in certainexample instances.

In certain situations, designers of coated articles often strive for acombination of high visible transmission, substantially neutral color,low emissivity (or emittance), and low sheet resistance (R_(S)). Highvisible transmission for example may permit coated articles to be moredesirable in certain window applications, whereas low-emissivity (low-E)and low sheet resistance characteristics permit such coated articles toblock significant amounts of IR radiation so as to reduce for exampleundesirable heating of vehicle or building interiors.

However, heat treatment of coated articles typically requires use oftemperature(s) of at least 580 degrees C., more preferably of at leastabout 600 degrees C. and still more preferably of at least 620 degreesC. The use of such high temperatures (e.g., for 5-10 minutes or more)often causes coatings to break down and/or causes one or more of theaforesaid desirable characteristics to significantly deteriorate in anundesirable manner. Those in the art strive for heat treatability incertain applications, coupled with acceptable optical and solarcharacteristics.

Consider the following heat treatable coated article with thebelow-listed layer stack, where the layers are listed in order from the6 mm thick clear glass substrate outwardly.

Layer Glass Substrate Thickness (Å) TiO₂ 33.1 Si₃N₄ 110 ZnO 100 Ag 107NiCrO_(x) 36.5 SnO₂ 482.7 Si₃N₄ 110 ZnO 100 Ag 159.5 NiCrO_(x) 36.5 SnO₂100 Si₃N₄ 193.4

While the aforesaid coated article is heat treatable, there is room forimprovement with regard to thermal stability. For example, as shown inFIGS. 2-5, lengthy heat treatments at high temperatures tend to causethis coated article to suffer significant drops in visible transmission,significant changes in certain color value(s), and significant increasesin sheet resistance (R_(S)). There is room for improvement in one ormore of these respects.

Additionally, the aforesaid coated article is susceptible to scratchingin certain instances, and is also sometimes characterized by high hazevalues following heat treatment.

In view of the above, it will be apparent to those skilled in the artthat there exists a need for coated articles which are capable ofrealizing (a) improved thermal stability with regard to visibletransmission, color, emissivity (or emittance), and/or sheet resistance(R_(S)); (b) improved mechanical durability such as scratch resistance;and/or (c) improved haze characteristics. In certain exampleembodiments, it may be desired that one or all of these characteristicscan be achieved.

BRIEF SUMMARY OF EXAMPLE EMBODIMENTS OF THE INVENTION

In certain example embodiments of this invention, an interlayercomprising tin oxide is provided under an infrared (IR) reflecting layerso as to be located between respective layers comprising silicon nitrideand zinc oxide.

Unexpectedly, it has been found that the use of such a tin oxideinclusive interlayer (or adhesion layer) results in significantlyimproved thermal stability, mechanical durability (e.g., scratchresistance), and haze characteristics.

For example, with regard to thermal stability, it has been found thatthe use of such a tin oxide inclusive interlayer results in a coatedarticle which is capable of realizing one or more of: (a) less visibletransmission shift due to heat treatment, (b) higher visibletransmission following heat treatment; (c) less shifting of certaincolor value(s) due to heat treatment, (d) substantially neutralcoloration following heat treatment; (e) more stable, or evendecreasing, sheet resistance due to heat treatment, (f) lower sheetresistance and thus lower emissivity following heat treatment, and/or(g) improved haze characteristics following heat treatment. It has alsobeen found that the provision of this tin oxide inclusive interlayer isalso capable of significantly improving mechanical durability and hazecharacteristics of the coated article, compared to if the layer were notpresent:

These surprisingly results, which in certain example instances areassociated with the use of the combination layer stack portion of glass. . . Si_(x)N_(y)/SnO₂/ZnO/Ag . . . , are highly advantageous, sincemechanical durability, higher visible transmission, lower emissivity,lower sheet resistance, reduced haze, and/or improved thermal stabilityare typically desired features in coated articles.

In certain example embodiments of this invention, there is provided acoated article comprising a coating supported by a glass substrate, thecoating comprising: a first dielectric layer; a first infrared (IR)reflecting layer comprising silver located over at least the dielectriclayer; a first layer comprising silicon nitride located over at leastthe first IR reflecting layer and the first dielectric layer; a firstlayer comprising tin oxide located over and contacting the first layercomprising silicon nitride; a first layer comprising zinc oxide locatedover and contacting the first layer comprising tin oxide, so that thefirst layer comprising tin oxide is located between and contacting thefirst layer comprising silicon nitride and the first layer comprisingzinc oxide; a second IR reflecting layer comprising silver located overand contacting the first layer comprising zinc oxide; and at leastanother dielectric layer located over at least the second IR reflectinglayer.

In certain other example embodiments of this invention, there isprovided a coated article comprising a coating supported by a glasssubstrate, the coating comprising from the glass substrate outwardly: alayer comprising silicon nitride; a layer comprising tin oxide locatedover and contacting the layer comprising silicon nitride; a layercomprising zinc oxide located over and contacting the layer comprisingtin oxide, so that the layer comprising tin oxide is located between andcontacting the layer comprising silicon nitride and the layer comprisingzinc oxide; an infrared (IR) reflecting layer located over andcontacting the layer comprising zinc oxide; and at least anotherdielectric layer located over at least the IR reflecting layer.

In certain other example embodiments of this invention, there isprovided a coated article including: a coating supported by a glasssubstrate, wherein the coating comprises first and second IR reflectinglayers comprising silver which are spaced apart from one another by atleast one layer comprising tin oxide, and wherein the coated article iscapable of being heat treated for 18 minutes at a furnace temperature ofabout 650 degrees C. without realizing a sheet resistance increase ofmore than 0.1 ohms/square and/or a visible transmission decrease of morethan 1% from the 8 minute mark to the 18 minute mark of such heattreatment, measured monolithically.

In still further example embodiments of this invention, there isprovided a coated article including: a coating supported by a glasssubstrate, wherein the coating comprises first and second IR reflectinglayers comprising silver which are spaced apart from one another by atleast one layer comprising tin oxide, and wherein the coated article iscapable of being heat treated at a furnace temperature of about 650degrees C. for 12 minutes, and realizing at least one of the followingdue to such heat treatment: (a) a visible transmission that does notdecrease between the and 12 minute marks of such heat treatment; (b) atransmissive b* value which does not change by more than 0.5 from the 8minute mark to the 12 minute mark of such heat treatment; and (c) asheet resistance in units of ohms/square which does not increase fromthe 8 minute mark to the 12 minute mark of such heat treatment.

In other example embodiments of this invention, there is provided acoated article comprising a coating supported by a glass substrate, thecoating comprising: a first dielectric layer; a first infrared (IR)reflecting layer comprising silver located over at least the dielectriclayer; a first layer comprising silicon nitride located over at leastthe first IR reflecting layer and the first dielectric layer; a firstlayer comprising a metal oxide located over and contacting the firstlayer comprising silicon nitride; a first layer comprising zinc oxidelocated over and contacting the first layer comprising the metal oxide,so that the first layer comprising the metal oxide is located betweenand contacting the first layer comprising silicon nitride and the firstlayer comprising zinc oxide; a second IR reflecting layer comprisingsilver located over and contacting the first layer comprising zincoxide; and at least another dielectric layer located over at least thesecond IR reflecting layer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional view of a coated article according to anexample embodiment of this invention.

FIG. 2 is graph comparing changes in visible transmission (Ill. C, 2degree obs.) due to heat treatment for an example embodiment of thisinvention versus a Comparative Example (CE).

FIG. 3 is graph comparing changes in transmissive b* coloration (Ill. C,2 degree obs.) due to heat treatment for an example embodiment of thisinvention versus the Comparative Example (CE).

FIG. 4 is graph comparing changes in sheet resistance due to heattreatment for an example embodiment of this invention versus theComparative Example (CE).

FIG. 5 is graph comparing changes in transmitted haze due to heattreatment for an example embodiment of this invention versus theComparative Example (CE).

FIGS. 6( a) and 6(b) are surface morphology images illustrating improvedscratch resistance of an Example of this invention compared to aComparative Example (CE).

DETAILED DESCRIPTION OF EXAMPLES OF THE INVENTION

Coated articles herein may be used in applications such as IG windowunits, vehicle windows, monolithic architectural windows, residentialwindows, and/or any other suitable application that includes single ormultiple glass substrates.

In certain example embodiments of this invention, an interlayercomprising tin oxide or the like is provided under an infrared (IR)reflecting layer. In certain example embodiments, the interlayercomprising tin oxide is located between respective layers comprisingsilicon nitride and zinc oxide. Surprisingly, it has been found that theuse of such a tin oxide inclusive interlayer results in significantlyimproved thermal stability, improved mechanical durability (e.g.,scratch resistance) and/or improved haze characteristics. In certainexample embodiments of this invention, improved mechanical durability,thermal stability and/or corrosion resistance for heat-treatable low-Ecoated articles can be realized when thermodynamically stable silverbased layers are deposited, and the use of the tin oxide is believed toaid in providing such silver based layers even though the tin oxide isnot in direct contact with the silver in certain example embodiments ofthis invention. It is believed that the tin oxide may reduce damage tothe zinc oxide which may otherwise be caused by silicon nitride directlycontacting the zinc oxide in certain instances.

For example, with regard to thermal stability, it has unexpectedly beenfound that the use of such a tin oxide inclusive interlayer results in acoated article which is capable of realizing one or more of: (a) lessvisible transmission shift due to heat treatment, (b) higher visibletransmission following heat treatment; (c) less shifting of certaincolor value(s) due to heat treatment, (d) substantially neutralcoloration following heat treatment; (e) more stable, or evendecreasing, sheet resistance due to heat treatment, (f) lower sheetresistance and thus lower emissivity following heat treatment, and/or(g) improved haze characteristics following heat treatment. Scratchresistance is also remarkably improved as shown in FIGS. 6( a)-(b).

These surprisingly results, which in certain example instances areassociated with the use of the combination layer stack portion ofSi_(x)N_(y)/SnO₂/ZnO/Ag, are highly advantageous since mechanicaldurability, higher visible transmission, lower emissivity, lower sheetresistance, reduced haze, and/or improved thermal stability aretypically desired features in coated articles.

In certain example embodiments of this invention, the coating includes adouble-silver stack, although this invention is not so limited in allinstances.

For example, in certain example embodiments of this invention, heattreated coated articles having multiple IR reflecting layers two spacedapart silver based layers) are capable of realizing a sheet resistance(R_(S)) of less than or equal to 3.0 (more preferably less than or equalto 2.5, even more preferably less than or equal to 2.1, and mostpreferably less than or equal to 2.0). In certain example embodiments,following heat treatment and as measured in monolithic form, coatedarticles herein are capable of realizing a visible transmission (Ill. C,2 degree) of at least 75%, more preferably of at least 77%, and mostpreferably of at least 78%. Moreover, in certain example embodiments,following heat treatment and coupling to another glass substrate to forman IG window unit, IG window unit coated articles according to certainexample embodiments of this invention are capable of realizing a visibletransmission of at least 60%, more preferably of at least 65%, even morepreferably of at least 66%, and in certain embodiments of at least 67%.

The terms “heat treatment” and “heat treating” as used herein meanheating the article to a temperature sufficient to achieve thermaltempering, heat bending, and/or heat strengthening of the glassinclusive article. This definition includes, for example, heating acoated article in an oven or furnace at a temperature of least about 580degrees C., more preferably at least about 600 degrees C., for asufficient period to allow tempering, bending, and/or heatstrengthening. In certain instances, the HT may be for at least about 4or 5 minutes.

FIG. 1 is a side cross sectional view of a coated article according toan example non-limiting embodiment of this invention. The coated articleincludes substrate 1 (e.g., clear, green, bronze, or blue-green glasssubstrate from about 1.0 to 10.0 mm thick, more preferably from about1.0 mm to 3.5 mm thick), and coating (or layer system) 30 provided onthe substrate 1 either directly or indirectly. The coating (or layersystem) 30 includes: bottom dielectric layer 2 which may be of orinclude titanium oxide (e.g., TiO₂) or the like, dielectric siliconnitride layer 3 which may be Si₃N₄, of the Si-rich type for hazereduction, or of any other suitable stoichiometry in differentembodiments of this invention, first lower contact layer 7 (whichcontacts IR reflecting layer 9), first conductive and preferablymetallic infrared (IR) reflecting layer 9, first upper contact layer 11(which contacts layer 9), dielectric layer 13 (which may be deposited inone or multiple steps in different embodiments of this invention),another silicon nitride layer 14, tin oxide inclusive interlayer 15,second lower contact layer 17 (which contacts IR reflecting layer 19),second conductive and preferably metallic IR reflecting layer 19, secondupper contact layer 21 (which contacts layer 19), dielectric layer 23,and finally protective dielectric layer 25. The “contact” layers 7, 11,17 and 21 each contact at least one IR reflecting layer (e.g., layerbased on Ag). The aforesaid layers 2-25 make up low-E, (i.e., lowemissivity) coating 30 which is provided on glass or plastic substrate1.

In monolithic instances, the coated article includes only one glasssubstrate 1 as illustrated in FIG. 1. However, monolithic coatedarticles herein may be used in devices such as laminated vehiclewindshields, IG window units, and the like. A laminated vehicle windowsuch as a windshield typically includes first and second glasssubstrates laminated to one another via a polymer based interlayer(e.g., see U.S. Pat. No. 6,686,050, the disclosure of which isincorporated herein by reference). One of these substrates of thelaminate may support coating 30 on an interior surface thereof incertain example embodiments. As for IG window units, an IG window unitmay include two spaced apart substrates. An example IG window unit isillustrated and described; for example, in U.S. Pat. No. 6,632,491, thedisclosure of which is hereby incorporated herein by reference. Anexample JO window unit may include, for example, the coated glasssubstrate 1 shown in FIG. 1 coupled to another glass substrate viaspacer(s), sealant(s) or the like with a gap being defined therebetween.This gap between the substrates in IG unit embodiments may in certaininstances be filled with a gas such as argon (Ar). An example IG unitmay comprise a pair of spaced apart clear glass substrates each about 4mm thick, one of which is coated with a coating 30 herein in certainexample instances, where the gap between the substrates may be fromabout 5 to 30 mm, more preferably from about 10 to 20 mm, and mostpreferably about 16 mm. In certain example instances, the coating 30 maybe provided on the interior surface of either substrate facing the gap.

Dielectric layer 2 is in direct contact with the glass substrate 1, andis optional. Dielectric layer 2 may be of or include TiO_(x) in certainexample embodiments of this invention, where x is from 1.5 to 2.0, morepreferably about 2.0.

Dielectric layers 3 and 14 may be of or include silicon nitride incertain embodiments of this invention. Silicon nitride layers 3 and 14may, among other things, improve heat-treatability of the coatedarticles, e.g., such as thermal tempering or the like. The siliconnitride of layers 3 and/or 14 may be of the stoichiometric type (i.e.,Si₃N₄), or alternatively of the Si-rich type in different embodiments ofthis invention. For example, Si-rich silicon nitride 3 (and/or 14)combined with zinc oxide and/or tin oxide under a silver based IRreflecting layer may permit the silver to be deposited (e.g., viasputtering or the like) in a manner which causes its sheet resistance tobe lessened compared to if certain other material(s) were under thesilver. Moreover, the presence of free Si in a Si-rich silicon nitrideinclusive layer 3 may allow certain atoms such as sodium (Na) whichmigrate outwardly from the glass 1 during HT to be more efficientlystopped by the Si-rich silicon nitride inclusive layer before they canreach the silver and damage the same. Thus, it is believed that theoxidation caused by heat treatment allows visible transmission toincrease, and that the Si-rich Si_(x)N_(y) in layer 3 can reduce theamount of damage done to the silver layer(s) during HT in certainexample embodiments of this invention thereby allowing sheet resistance(R_(S)) to decrease or remain about the same in a satisfactory manner.

In certain example embodiments, when Si-rich silicon nitride us used inlayer 3 and/or 14, the Si-rich silicon nitride layer as deposited may becharacterized by Si_(x)N_(y) layer(s), where x/y may be from 0.76 to1.5, more preferably from 0.8 to 1.4, still more preferably from 0.85 to1.2. Moreover, in certain example embodiments, before and/or after HTthe Si-rich Si_(x)N_(y) layer(s) may have an index of refraction “n” ofat least 2.05, more preferably of at least 2.07, and sometimes at least2.10 (e.g., 632 nm) (note: stoichiometric Si₃N₄ which may also be usedhas an index “n” of 2.02-2.04). In certain example embodiments, it hassurprisingly been found that improved thermal stability is especiallyrealizable when the Si-rich Si_(x)N_(y) layer(s) as deposited has anindex of refraction “n” of at least 2.10, more preferably of at least2.20, and most preferably from 2.2 to 2.4. Also, the Si-rich Si_(x)N_(y)layer in certain example embodiments may have an extinction coefficient“k” of at least 0.001, more preferably of at least 0.003 (note:stoichiometric Si₃N₄ has an extinction coefficient “k” of effectively0). Again, in certain example embodiments, it has surprisingly beenfound that improved thermal stability can be realized when “k” for theSi-rich Si_(x)N_(y) layer(s) is from 0.001 to 0.05 as deposited (550nm). It is noted that n and k tend to drop due to heat treatment.

Any and/or all of the silicon nitride layers discussed herein may bedoped with other materials such as stainless steel or aluminum incertain example embodiments of this invention. For example, any and/orall silicon nitride layers discussed herein may optionally include fromabout 0-15% aluminum, more preferably from about 1 to 10% aluminum., incertain example embodiments of this invention. The silicon nitride maybe deposited by sputtering a target of Si or SiAl in certain embodimentsof this invention.

Infrared (IR) reflecting layers 9 and 19 are preferably substantially orentirely metallic and/or conductive, and may comprise or consistessentially of silver (Ag), gold, or any other suitable IR reflectingmaterial. IR reflecting layers 9 and 19 help allow the coating to havelow-E and/or good solar control characteristics. The IR reflectinglayers may, however, be slightly oxidized in certain embodiments of thisinvention.

The upper contact layers 11 and 21 may be of or include nickel (Ni)oxide, chromium/chrome (Cr) oxide, or a nickel alloy oxide such asnickel chrome oxide (NiCrO_(x)), or other suitable material(s), incertain example embodiments of this invention. The use of, for example,NiCrO_(x) in these layers (11 and/or 21) allows durability to beimproved. The NiCrO_(x) of layers 11 and/or 21 may be fully oxidized incertain embodiments of this invention (i.e., fully stoichiometric), oralternatively may only be partially oxidized. In certain instances, theNiCrO_(x) layers 11 and/or 21 may be at least about 50% oxidized.Contact layers 11 and/or 21 (e.g., of or including an oxide of Ni and/orCr) may or may not be oxidation graded in different embodiments of thisinvention. Oxidation grading means that the degree of oxidation in thelayer changes throughout the thickness of the layer so that for examplea contact layer may be graded so as to be less oxidized at the contactinterface with the immediately adjacent IR reflecting layer than at aportion of the contact layer(s) further or more/most distant from theimmediately adjacent IR reflecting layer. Descriptions of various typesof oxidation graded contact layers are set forth in U.S. Pat. No.6,576,349, the disclosure of which is hereby incorporated herein byreference. Contact layers 11 and/or 21 (e.g., of or including an oxideof Ni and/or Cr) may or may not be continuous in different embodimentsof this invention across the entire IR reflecting layer.

Dielectric layer 13 may be of or include tin oxide in certain exampleembodiments of this invention. However, as with other layers herein,other materials may be used in different instances.

Lower contact layers 7 and/or 17 in certain embodiments of thisinvention are of or include zinc oxide (e.g., ZnO). The zinc oxide oflayers 7 and 17 may contain other materials as well such as Al (e.g., toform ZnAlO_(x)). For example, in certain example embodiments of thisinvention, one or more of zinc oxide layers 7, 17 may be doped with fromabout 1 to 10% Al, more preferably from about 1 to 5% Al, and mostpreferably about 1 to 4% Al.

interlayer 15 of or including tin oxide is provided under IR reflectinglayer 19 so as to be located between silicon nitride layer 14 and zincoxide layer 17. Surprisingly, as explained above, it has been found thatthe use of such a tin oxide inclusive interlayer 15 results in numerousimprovements compared to a situation where the layer is not provided.For example, it has been found that the use of such a tin oxideinclusive interlayer 15 results in a coated article which is capable ofrealizing: (a) less visible transmission shift due to heat treatment,(b) higher visible transmission following heat treatment; (c) lessshifting of certain color value(s) due to heat treatment, (d)substantially neutral coloration following heat treatment; (e) morestable, or even decreasing, sheet resistance due to heat treatment, (f)lower sheet resistance and thus lower emissivity following heattreatment, (g) improved haze characteristics following heat treatment,and/or (h) improved mechanical durability such as scratch resistancebefore and/or after heat treatment. Thus, in certain example embodimentsof this invention, coated articles may be taken to higher temperaturesduring heat treatment and/or for longer times without sufferingundesirable significant transmission drops and/or increases in sheetresistance. In certain alternative embodiments, it is possible to dopethe tin oxide of layer 15 with other materials such as Al, Zn or thelike. Alternatively, other metal oxide(s) may be used for layer 15 incertain instances.

Dielectric layer 23 may be of or include tin oxide in certain exampleembodiments of this invention. However, layer 23 is optional and neednot be provided in certain example embodiments of this invention.Dielectric layer 25, which may be an overcoat in certain exampleinstances, may be of or include silicon nitride (e.g., Si₃N₄) or anyother suitable material in certain example embodiments of thisinvention. Optionally, other layers may be provided above layer 25.Layer 25 is provided for durability purposes, and to protect theunderlying layers during heat treatment and/or environmental use. Incertain example embodiments, layer 25 may have an index of refraction(n) of from about 1.9 to 2.2, more preferably from about 1.95 to 2.05.

Other layer(s) below or above the illustrated coating may also beprovided. Thus, while the layer system or coating is “on” or “supportedby” substrate 1 (directly or indirectly), other layer(s) may be providedtherebetween. Thus, for example, the coating of FIG. 1 may be considered“on” and “supported by” the substrate 1 even if other layer(s) areprovided between layer 2 and substrate 1. Moreover, certain layers ofthe illustrated coating may be removed in certain embodiments, whileothers may be added between the various layers or the various layer(s)may be split with other layer(s) added between the split sections inother embodiments of this invention without departing from the overallspirit of certain embodiments of this invention.

While various thicknesses and materials may be used in layers indifferent embodiments of this invention, example thicknesses andmaterials for the respective layers on the glass substrate 1 in the FIG.1 embodiment are as follows, from the glass substrate outwardly:

Example Materials/Thicknesses; FIG. 1 Embodiment

Layer Preferred More Glass (1-10 mm thick) Range ({acute over (Å)})Preferred ({acute over (Å)}) Example (Å) TiO₂ (layer 2) 10-120 Å 20-80 Å33 Å Si_(x)N_(y) (layer 3) 40-450 Å 70-300 Å 110 Å ZnO_(x) (layer 7)10-300 {acute over (Å)} 40-150 {acute over (Å)} 100 Å Ag (layer 9)50-250 {acute over (Å)} 80-120 {acute over (Å)} 107 Å NiCrO_(x) (layer11) 10-100 {acute over (Å)} 12-40 {acute over (Å)} 18 Å SnO₂ (layer 13)0-1,000 Å 200-700 Å 382 Å Si_(x)N_(y) (layer 14) 50-450 {acute over (Å)}80-200 {acute over (Å)} 110 Å SnO₂ (layer 15) 30-250 Å 50-200 Å 100 ÅZnO_(x) (layer 17) 10-300 {acute over (Å)} 40-150 {acute over (Å)} 100 ÅAg (layer 19) 50-250 {acute over (Å)} 80-220 {acute over (Å)} 159 ÅNiCrO_(x) (layer 21) 10-100 {acute over (Å)} 20-45 {acute over (Å)} 36 ÅSnO₂ (layer 23) 0-750 Å 40-200 Å 100 Å Si₃N₄ (layer 25) 0-750 {acuteover (Å)} 80-320 {acute over (Å)} 193 Å

In certain example embodiments of this invention, coated articles hereinmay have the following optical and solar characteristics set forth inTable 2 when measured monolithically (before any optional HT). The sheetresistances (R_(S)) herein take into account all IR reflecting layers(e.g., silver layers 9, 19).

Optical/Solar Characteristics (Monolithic; pre-HT) CharacteristicGeneral More Preferred Most Preferred R_(s) (ohms/sq.): <=5.0 <=4.0<=3.0 E_(n): <=0.07 <=0.04 <=0.03 T_(vis) (Ill. C. 2°): >=70% >=74%>=75%

In certain example embodiments, coated articles herein may have thefollowing characteristics, measured monolithically for example, afterheat treatment (HT):

Optical/Solar Characteristics (Monolithic; post-HT) CharacteristicGeneral More Preferred Most Preferred R_(s) (ohms/sq.): <=3.0 <=2.5<=2.1 (or <=2.0) E_(n): <=0.07 <=0.04 <=0.03 T_(vis) (Ill. C.2°): >=75% >=77% >=78% Transmitted Haze: <=0.6 <=0.5 <=0.4

Moreover, in certain example laminated embodiments of this invention,coated articles herein which have been heat treated to an extendsufficient for tempering, and which have been coupled to another glasssubstrate to form an JO unit, may have the following IG unitoptical/solar characteristics.

Example Optical Characteristics (IG Unit: Post-HT)

Characteristic General More Preferred T_(vis) (or TY)(Ill. C.2°): >=60% >=69% a*_(t) (Ill. C. 2°): −6 to +1.0 −5 to 0.0 b*_(t) (Ill.C. 2°): −2.0 to +8.0 0.0 to 4.0 L* (Ill. C. 2°): 80-95 84-95 R_(f)Y(Ill. C., 2 deg.): 1 to 13% 1 to 12% a*_(f) (Ill. C., 2°): −5.0 to +2.0−4.0 to +0.5 b*_(f) (Ill. C., 2°): −14.0 to +10.0 −4.0 to +3.5 L* (Ill.C. 2°): 30-45 33-41 R_(g)Y (Ill. C., 2 deg.): 1 to 12% 1 to 10% a*_(g)(Ill. C., 2°): −5.0 to +2.0 −2.5 to +0.5 b*_(g) (Ill. C., 2°): −10.0 to+10.0 −5.0 to 0 L* (Ill. C. 2°): 30-40 33-38 SHGC (surface 2): <=0.42<=0.38 SHGC (surface 3): <=0.47 <=0.45

The following examples are provided for purposes of example only, andare not intended to be limiting unless specifically claimed.

EXAMPLES

The following Examples were made via sputtering on 6 mm thick clearglass substrates so as to have approximately the layer stacks set forthbelow. Example 1 is according to an example embodiment of this inventionas shown in FIG. 1, whereas the Comparative Example is provided forpurposes of comparison. The thicknesses are in units of angstroms (Å)and are approximations.

Layer Glass Substrate Comparative Example Example 1 TiO₂ 33.1 33.1 Si₃N₄110 110 ZnO 100 100 Ag 107 107 NiCrO_(x) 36.5 18.3 SnO₂ 482.7 382.7Si₃N₄ 110 110 SnO₂ 0 100 ZnO 100 100 Ag 159.5 159.5 NiCrO_(x) 36.5 36.5SnO₂ 100 100 Si₃N₄ 193.4 193.4

It can be seen from the above that Example 1 and the Comparative Exampleare similar, except the tin oxide interlayer 15 is provided in Example 1but is not in the Comparative Example. After being sputter depositedonto the glass substrates, the Example coated articles were heat treatedin a manner sufficient for tempering.

FIGS. 2-5 compare Example 1 (IMP) to the Comparative Example (STD) withregard to thermal stability behavior/characteristics during and afterheat treatments. FIGS. 2-5 are based on monolithic measurements, andfurnace exposure time in minutes at about 650 degrees C. Of course,during heat treatment, the coated articles need not be heat treated foras long as is shown in FIGS. 2-5; FIGS. 2-5 illustrate lengthy heattreatment at high temperature in order to emphasize certain advantagesof certain example embodiments of this invention.

FIG. 2 illustrates that visible transmission for the Comparative Example(STD) significantly dropped during heat treatment, whereas the visibletransmission of Example 1 (IMP) did not. Thus, it can be seen that theprovision of the tin oxide inclusive interlayer 15 in the coated articleof Example 1 surprisingly resulted in less visible transmission shiftduring heat treatment, and is also capable of allowing higher visibletransmission in the post-HT coated article.

FIG. 3 illustrates that transmissive b* coloration for the ComparativeExample (STD) significantly changed (i.e., from about 0.7 to almost−1.0) during heat treatment, whereas the b* value for Example 1 (IMP)did not shift as much. Thus, it can be seen that the provision of thetin oxide inclusive interlayer 15 in the coated article of Example 1surprisingly resulted in less transmissive b* color shift during heattreatment, and is also capable of allowing more neutral b* coloration inthe post-HT coated article.

FIG. 4 illustrates that sheet resistance (R_(S)) of the ComparativeExample (STD) significantly increased during heat treatment, whereas thesheet resistance of Example 1 (IMP) did not. Thus, it can be seen thatthe provision of the tin oxide inclusive interlayer 15 in the coatedarticle of Example 1 surprisingly resulted in less sheet resistanceincrease during heat treatment, and is also capable of allowing improved(i.e., lower) sheet resistance in the post-HT coated article.

FIG. 5 illustrates that transmitted haze of the Comparative Example(STD) significantly increased much more than did that of Example 1(IMP). Thus, it can be seen that the provision of the tin oxideinclusive interlayer 15 in the coated article of Example 1 surprisinglyresulted in improved haze characteristics in the post-HT coated article.

It can be seen from FIGS. 2-5 that coated articles according to certainexample embodiments of this invention are capable of being heat treatedat a furnace temperature of about 650 degrees C. for 18 minutes, andrealizing at least one of the following due to such heat treatment: (a)a visible transmission that does not decrease by more than 1% due tosuch heat treatment from the 8 minute mark to the 18 minute mark, andwhich preferably does not decrease at all due to such heat treatmentfrom the 8 minute mark to the 18 minute mark; (b) a transmissive b*value which does not change by more than 1.0 from the 8 minute mark tothe 18 minute mark, more preferably does not change by more than 0.5,and most preferably does not change by more than 0.3 due to such heattreatment from the 8 minute mark to the 18 minute mark; (c) a sheetresistance in units of ohms/square which does not increase by more than0.1 due to such heat treatment from the 8 minute mark to the 18 minutemark, and which preferably does not increase at all due to such heattreatment from the 8 minute mark to the 18 minute mark; and (d) atransmitted haze value which does not increase by more than 0.5 due tosuch heat treatment from the 8 minute mark to the 18 minute mark, andwhich preferably is no greater than about 0.5 after such heat treatmentmeasured monolithically.

In certain other example embodiments of this invention, coated articleswith two silver based layers are capable of being heat treated at afurnace temperature of about 650 degrees C. for 12 minutes, andrealizing at least one of the following due to such heat treatment: (a)a visible transmission that does not decrease between the and 12 minutemarks of such heat treatment; (b) a transmissive b* value which does notchange by more than 1.0, more preferably does not change by more than0.5, and most preferably does not change by more than 0.3 from the 8minute mark to the 12 minute mark of such heat treatment; (c) a sheetresistance in units of ohms/square which does not increase from the 8minute mark to the 12 minute mark of such heat treatment.

In view of FIGS. 2-5 discussed above, example advantage and unexpectedresults associated with certain example embodiments of this inventionare clear.

FIGS. 6( a)-6(b) illustrate the surprisingly improved scratch resistancecharacteristics associated with certain example embodiments of thisinvention. FIG. 6( a) is a surface morphology image of scratches for theComparative Example, whereas FIG. 6( b) is a surface morphology image ofscratches for Example 1. It can be seen that Example 1 was much lesssusceptible to scratching than was the Comparative Example. Inparticular, the Comparative Example in FIG. 6( a) realized much tallerfeatures compared to Example 1 in FIG. 6( b) (about 6,000 Å compared toabout 3,000 Å). Moreover, the Comparative Example in FIG. 6( a) realizedmuch wider features compared to Example 1 in FIG. 6( b). Thesemechanical durability problems associated with the Comparative Example,shown in FIG. 6( a), often result in delamination which of course isundesirable. In contrast, the improved features of Example 1 shown inFIG. 6( b) do not result in delamination, thereby evidencing thesignificantly improved mechanical durability associated with certainexample embodiment of this invention.

It is noted that before and after heat treatment for about eight minutesat a furnace temperature of about 650 degrees C., the coated article ofExample 1 had the following characteristics, measured monolithically.

Example 1 Monolithic, Before/after HT

Characteristic pre-HT Post-HT T_(vis) (or TY)(Ill. C. 2°): 72.82% 78.53%a*_(t) (Ill. C. 2°): −2.96 −1.79 b*_(t) (Ill. C. 2°): 2.49 0.02 R_(f)Y(Ill. C., 2 deg.): 6.56% 5.97% a*_(f) (Ill. C., 2°): −6.75 −7.99 b*_(f)(Ill. C., 2°): 9.89 7.20 L* (Ill. C. 2°): 30.77 29.35 R_(g)Y (Ill. C., 2deg.): 7.21% 5.94% a*_(g) (Ill. C., 2°): −1.31 −1.99 b*_(g) (Ill. C.,2°): 0.79 −1.53 L* (Ill. C. 2°): 32.29 29.26 R_(s) (ohms/square): 2.682.04 Haze: 0.15 0.12

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims.

1. A coated article including a coating supported by a glass substrate,the coating comprising: a first dielectric layer; a layer comprisingzinc oxide on the glass substrate over at least the first dielectriclayer; a first IR reflecting layer; a second IR reflecting layer; adielectric film located between at least the first and second IRreflecting layers; another dielectric film located above the first andsecond IR reflecting layers; wherein the dielectric film located betweenthe first and second IR reflecting layers comprises first and secondlayers comprising tin oxide that are spaced apart by at least a layercomprising silicon nitride; and wherein each of the first and secondlayers comprising tin oxide consist essentially of tin oxide.
 2. Thecoated article of claim 1, wherein another layer comprising zinc oxideis located below and directly contacting the second IR reflecting layer.3. The coated article of claim 1, wherein a layer comprising an oxide oftitanium is located between the glass substrate and the first dielectriclayer.
 4. The coated article of claim 1, wherein a layer comprising anoxide of NiCr is located over and directly contacting the first IRreflecting layer.
 5. The coated article of claim 1, where said anotherdielectric film located above the first and second IR reflecting layerscomprises a layer comprising silicon nitride located over a layercomprising tin oxide.
 6. The coated article of claim 1, where saidanother dielectric film located above the first and second IR reflectinglayers comprises a layer comprising tin oxide.
 7. The coated article ofclaim 1, wherein, said first layer comprising tin oxide is closer to theglass substrate than is the second layer comprising tin oxide, andwherein said first layer comprising tin oxide is thicker than the secondlayer comprising tin oxide.
 8. The coated article of claim 7, whereinsaid first layer comprising tin oxide is from 200-700 angstroms thickand said second layer comprising tin oxide is from 50-200 angstromsthick.
 9. The coated article of claim 1, wherein neither said first norsecond layer comprising tin oxide contacts a layer comprising silver.10. The coated article or claim 1, wherein said IR reflecting layerscomprise silver.
 11. The coated article of claim 1, wherein the firstand second layers comprising tin oxide each directly contact the layercomprising silicon nitride.
 12. The coated article of claim 1, whereinsaid layer comprising zinc oxide is located directly under andcontacting the first IR reflecting layer.